Shingle



Feb. 15, 1949. I M. s. OFElLLY 2,462,028

SHINGLE Filed July 25, 1946 fni/enir mr-mror z'g j Patented Feb. 15, 1949' SHINGLE Martin G. OReilly, Chicago, 111., assignor to Ford Roofing Products Company, Chicago, 111., a corporation of Illinois Application July 25, 1946, Serial No. 686,064

This invention relates to thick butt asphalt shingles. Among other objects the invention aims to provide an improved thick butt asphalt shingle having a longer life than has heretofore characterized shingles of this type.

The invention may be readily understood by reference to one illustrative shingle and its method of manufacture described in the following specification and illustrated in the accom-' panying drawing.

In said drawing:

Fig. 1 is a plan view of a shingle;

Fig. 2 is a longitudinal section thereof on the plane 2-2 of Fig. 1; and

Fig. 3 is a diagram illustrating the manner of forming the core of the shingle from stock material.

Thick butt shingles are desirable mainly because of the deeply textured appearance which they give to a roof. The increased weight and stiffness of such shingles are also desirable. Asphalt shingles of this type available on the market are generally made by applying to the lower portion or butt of a prepared asphalt shingle a plurality of layersin effect a mixture-of asphalt and mineral granules to build up a thick composite body. The granules inside the body of the asphalt are designed to give stiffness and stability to the layer. The usual final layer of surfacing granules is embedded in the top surface of the asphalt. Other materials than granules may be used to stiffen or stabilize the asphalt layer.

Despite the fact that an asphalt shingle of this character 'is expensive, it is nevertheless somewhat of a makeshift since asphalt is not adapted for formation into thick layers, particularly when exposed to sunlight. Contrary to common belief, asphalt deteriorates under the action of sunlight. Under prolonged action of sunlight certain fractions of the asphalt are broken down and can be leached or dissolved out of the asphalt by the action of rainwater. The altered asphalt becomes brittle and cracks. The cracks travel down through the asphalt layer and it breaks into a multitude of small fragments which are easily dislodged by wind and rain from the base of the shingle. The deeper the exposed layer of asphalt, the more severe the cracking and spalling of the asphalt. The cheaper grade of asphalt roofing wherein the exposed layer a; asphalt is relatively thin sets less vulnerable to sunlight deterioration than the expensive thick butt shingles. The probable explanation is that sharp cracks which cause spalling of the asphalt 3 Claims. (Cl. 108-8) cannot form so readily in a thin coating of asphalt, and furthermore the surfacing granules give a more effective protection to the thin layer of asphalt than is possible with a thick layer. Also asphalt inside the underlying fibers of the base material of the shingle is protected and is not thus vulnerable.

In the illustrative thick butt shingle the exposed layer of coating asphalt is only thick enough to anchor the surfacing granules, yet the butt of the shingle is substantially thicker than thick butt asphalt shingles heretofore available. The shingle comprises a waterproofed, non-vegetable core ll) coated on the upper face with the aforesaid thin layer of coating asphalt ll in which is embedded the usual surfacing 52 of mineral granules of appropriate color. The core or base Ill comprises mineral fibers such as fiber glass which unlike other fibrous materials here tofore available is compatible with asphalt and will not under the action of moisture destroy the bond of the asphalt layer thereto. Most fibrous materials, even roofing felt itself unless carefully processed, tend to disrupt the bond of the asphalt coating thereto. This fact is better understood than its explanation. The structure and characteristics of the fibrous material and the action of moisture probably share the major responsibility. In all of the base materials of vegetable origin thorough waterproofing and elimination of interfere with treatment and there is subsequently no tendency to absorb moisture. Absence of moisture also reduces the chilling or congealing of the asphalt at the surface of the material which would interfere with penetration of asphalt into the core. The very low specific heat of the fiber glass minimizes the chilling efiect on the asphalt, which remains fluid enough to penetrate adequately. Since the fiber glass is not of vegetable origin the asphalt may be heated to higher temperatures (which would char vegetable fiber) to obtain greater fluidity and therefore facilitate waterproofing; and the body of the shingle may if necessary be heated without danger. further to aid penetration. The asphalt saturant or waterproofing coats and bonds the glass fibers and tremendously increases the strength of the shingle. Yet it possesses a softness or lack of extreme rigidity which causes it to conform to the slight irregularities in the roof surface and in this respect is much superior to the rigid slate and tile shingles. It is unnecessary to strive for complete impregnation of the core as with a vegetable fiber core, for preservation and eliminating moisture. Mineral fiber will not deteriorate, and there is no tendency to retain or absorb moisture.

The waterproofing of the fiber glass body or core may be effected in various ways as by dipping, spraying or passing between heated rolls carrying the heated asphalt saturant. The saturant completely enters the core leaving no film on the surface and exposing the original textured surface of the core for subsequent bonding theretoof the layer of coating asphalt which is applied to the top surface, and if desired to the bottom edge or butt of the shingle. A layer of surfacing granules is then applied to the coating and partially embedded therein to provide a close textured weather surface. The shingle is much more resistant to the action of sunlight and other deteriorating forces, than the conventional asphalt shingle. The disrupting action of moisture on the coating is absent. Moreover the asphalt coating is so thin and well bonded to the core that it cannot be dislodged even if it contain surface cracks.

The asphalt saturant gives the shingle excellent nailing qualities, and there is no danger of cracking or breaking of the shingle as an incident to the nailing operation. The shingle may be easily cut with a knife or shear when small sections are needed.

The tapered mineral fiber core in may advantageously be made from stock board, e. g. in thickness, by splitting a board of the proper dimensions along a diagonal plane i3 into two tapered cores, as illustrated in Fig. 3. The fiber glass board is initially molded or formed by the manufacturer with a small amount of binder which gives the board enough stiffness for handling and for forming to accurate and uniform dimensions and thickness. In this condition sections of the board of a width equal substantially to the depth of the shingle may be readily split along the diagonal plane as aforesaid. Preferably the top of the shingle is not formed to a feathered or sharp edge. This may be accomplished by trimming off the excessively thin edge of the shingle or, as here shown, by shifting the diagonal splitting plane l3 so that it includes a portion of the edge of the original board. This will reduce the thickness of the butt or require the use of a thicker board to obtain a butt of the desired thickness.

The illustrative thick butt asphalt shingle is unique in that it combines strength, lack of extreme. rigidity, durability and thickness. Its thickness and durability place it in the class of slate and tile, yet its other qualities make it superior thereto in case of application and maintenance.

Obviously the invention is not limited to the details of the illustrative shingle or its method of manufacture. Moreover it is not indispensable that all features of the invention be used conjointly since various features may be used to advantage in different combinations and sub-combinations.

Having described my invention, I claim:

1. A thick butt shingle comprising in combination a preformed tapered self-sustaining body of fiber glass about /2 inch thick at its butt, said body being partly impregnated with asphalt to stiffen the same without rendering it rigid and providing-a shingle adapted to receive and hold attaching nails, said body having bonded directly to its upper surface a thin layer of coating asphalt in which is partly imbedded a surface layer P of granular mineral material.

2. A thick butt shingle comprising in combination a self-sustaining tapered body about inch thick at its butt and formed from porous fiber glass board, said body being impregnated with sufficient asphalt saturant to reinforce and stiffen it without rendering it rigid, said body having bonded directly to its upper surface a thin layer of coating asphalt in which is partly imbedded a surface layer of granular mineral material.

3. A thick butt shingle comprising in combination a self-sustaining tapered body about V inch thick at its butt and formed from porous fiber glass board, said body being impregnated with sufficient asphalt saturant to reinforce and stiffen it without rendering it rigid, said body having bonded directly to its upper surface a thin layer of coating asphalt in which is partly imbedded a surface layer of granular mineral material, said saturant lying substantially completely inside said body so as to expose the original textured surface of said body for mechanically anchoring said coating directly to said body.

MARTIN G. OREILLY.

REFERENCES CITED The following references are of record in the file of this patent:

UNITED STATES PATENTS Number Name Date 1,807,485 Robinson May 26, 1931 2,175,226 Slayter Oct. 10, 1939 2,316,093 Mac Nutt Apr. 6, 1943 

